The present invention relates generally to the field of inductive power transfer and more specifically to an inverter for use in inductive power transfer applications.
Inductive Power Transfer is a well-known type of power transfer permitting the transmission of electrical power from a power source to a consuming power device without using conductors. In general terms, it comprises the use of time-varying electromagnetic fields typically transmitted across an air gap to the consuming device. The power is transferred through induction which relies on a magnetic field generated in a transmitter (or primary coil) by an electric current to induce a current in a receiver (or secondary coil). This is the action employed in, for example, a transformer where the primary coil and secondary coil are not connected.
However, the primary and secondary coils of a transformer are in very close proximity with a high coupling factor. For other applications, to maintain a high power of transmission, there is a need for more efficient, powerful and/or multi-megahertz switching resonant inverters.
According to the present invention there is provided an inverter for inductive power transfer, the inverter comprising: a first inductor and a switching element in series between power supply terminals, the switching element being operable to be switched at a first frequency; a first capacitance in parallel with the switching element between the first inductor and a power supply terminal; a first tank circuit in parallel with the first capacitance, the first tank circuit comprising a second inductor and a second capacitance, wherein the second capacitance is arranged in series with the second inductor; a second tank circuit in parallel with the first capacitance; and a third capacitance in series with the first inductor between the first tank circuit and the second tank circuit, wherein the second tank circuit comprises a transmitter coil and a fourth capacitance, the fourth capacitance being arranged in parallel or series with the transmitter coil; wherein the fourth capacitance is selected such that the resonant frequency of the second tank circuit is not equal to the first frequency, and wherein the second inductor and the second capacitance are selected such that the resonant frequency of the first tank circuit is an integer multiple, greater than one, of the first frequency.
The present invention also provides an inductive power transfer transmitter comprising an inverter as described above and a controller operable to switch the switching element of the inverter at the first frequency.
Moreover, the present invention provides an inductive power transfer system comprising an inductive power transfer transmitter as defined above and an inductive power transfer receiver comprising a receiver coil spaced apart from the transmitter coil of the inductive power transfer transmitter.
The present invention also provides a method for inductive power transfer, comprising: providing an inverter comprising a first inductor and a switching element in series between power supply terminals, the switching element being operable to be switched at a first frequency; a first capacitance in parallel with the switching element between the first inductor and a power supply terminal; a first tank circuit in parallel with the first capacitance, the first tank circuit comprising a second inductor and a second capacitance, wherein the second capacitance is arranged in series with the second inductor; a second tank circuit in parallel with the first capacitance; and a third capacitance in series with the first inductor between the first tank circuit and the second tank circuit, wherein the second tank circuit comprises a transmitter coil and a fourth capacitance, the fourth capacitance being arranged in parallel or series with the transmitter coil; wherein the fourth capacitance is selected such that the resonant frequency of the second tank circuit is not equal to the first frequency; and wherein the second inductor and the second capacitance are selected such that the resonant frequency of the first tank circuit is double the first frequency; and wherein the ratio of the first capacitance to the second capacitance is greater than or equal to 0.7 and less than or equal to 1; and switching the switching element at the first frequency with a duty cycle greater than or equal to 0.35 and less than or equal to 0.40.
The present invention also provides a method for inductive power transfer, comprising: providing an inverter comprising a first inductor and a switching element in series between power supply terminals, the switching element being operable to be switched at a first frequency; a first capacitance in parallel with the switching element between the first inductor and a power supply terminal; a first tank circuit in parallel with the first capacitance, the first tank circuit comprising a second inductor and a second capacitance, wherein the second capacitance is arranged in series with the second inductor; a second tank circuit in parallel with the first capacitance; and a third capacitance in series with the first inductor between the first tank circuit and the second tank circuit, wherein the second tank circuit comprises a transmitter coil and a fourth capacitance, the fourth capacitance being arranged in parallel or series with the transmitter coil; wherein the fourth capacitance is selected such that the resonant frequency of the second tank circuit is not equal to the first frequency; and wherein the second inductor and the second capacitance are selected such that the resonant frequency of the first tank circuit is double the first frequency; and wherein the ratio of the first capacitance to the second capacitance is greater than 1 and less than 5; and switching the switching element at the first frequency with a duty cycle greater than 0.35 and less than 0.40.
The present invention also provides a method for inductive power transfer, comprising: providing an inverter comprising a first inductor and a switching element in series between power supply terminals, the switching element being operable to be switched at a first frequency; a first capacitance in parallel with the switching element between the first inductor and a power supply terminal; a first tank circuit in parallel with the first capacitance, the first tank circuit comprising a second inductor and a second capacitance, wherein the second capacitance is arranged in series with the second inductor; a second tank circuit in parallel with the first capacitance; and a third capacitance in series with the first inductor between the first tank circuit and the second tank circuit, wherein the second tank circuit comprises a transmitter coil and a fourth capacitance, the fourth capacitance being arranged in parallel or series with the transmitter coil; wherein the fourth capacitance is selected such that the resonant frequency of the second tank circuit is not equal to the first frequency; and wherein the second inductor and the second capacitance are selected such that the resonant frequency of the first tank circuit is double the first frequency; and wherein the ratio of the first capacitance to the second capacitance is greater than or equal to 20; switching the switching element at the first frequency with a duty cycle greater than or equal to 0.35 and less than or equal to 0.40.
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numbers are used for like elements, and in which:
At present, inductive power transfer inverters are based on either a Class D or Class E type of inverter. The Class D type inverters consist of two switching elements and deliver a limited output power at minimum voltage and with low current stresses across the switching elements. Class E type inverters consist of a single switching element and deliver a higher output power, but with higher voltage and higher current stresses across the switching element.
Inverters that can deliver a high output power capability are severely limited by the high voltage and current stresses that are present across the switching elements. Previously, this has meant employing higher-specified, and therefore more expensive, components. The present inventors have addressed this problem by devising a new inverter.
On embodiment of the new inverter is depicted in
The inverter 101 depicted in
In this embodiment, the switching element Q1 is a MOSFET, although other types of transistor can be employed instead.
In this embodiment, the inverter 101 also comprises a first capacitance C1 in parallel with the switching element Q1 between the first inductor L1 and a power supply terminal. However, as will be explained below, the capacitance C1 may be a capacitance of the switching element Q1 and so a separate capacitor C1 need not be provided.
A first tank circuit 1011 is arranged in parallel with the first capacitance C1, the first tank circuit 1011 comprising a second inductor L2 and a second capacitance C2, wherein the second capacitance C2 is arranged in series with the second inductor L2. The second inductor L2 and the second capacitance C2 are selected such that the resonant frequency of the first tank circuit 1011 is an integer multiple, greater than one, of the first frequency fs.
The inverter 101 is therefore a hybrid inverter which can be referred to as a Class EFn or Class E/Fn inverter. The subscript n refers to the ratio of the resonant frequency of the first tank circuit 1011 to the first frequency fs of the inverter 101 and is an integer multiple greater than or equal to 2. The EFn term is used if n is an even integer and the E/Fn term is used if n is an odd integer.
As will be explained in more detail below, the resonant frequency of the first tank circuit 1011 need not be precisely an integer multiple (greater than one) of the first frequency fs to achieve the advantages described herein, but instead can be equal to the integer multiple ±0.05. Accordingly, when any of the terms “integer multiple”, “twice”, “double”, “triple”, “three times”, etc. or the like are used herein to refer to the relationship between the resonant frequency of the first tank circuit 1011 and the first frequency fs, these terms should be understood to encompass the ±0.05 tolerance.
The inverter 101 also comprises a second tank circuit 1012 in parallel with the first capacitance C1.
The inverter 101 further comprises a third capacitance C3 in series with the first inductor L1 between the first tank circuit 1011 and the second tank circuit 1012.
The second tank circuit 1012 comprises a transmitter coil 1013, which is modelled as a third inductance L3 and a resistance RL in the circuit shown in
The fourth capacitance C4 is selected such that the resonant frequency of the second tank circuit is not equal to the first frequency fs. As a result, the inverter 101 operates in a semi-resonant mode. For example, the fourth capacitance C4 can be arranged in parallel with the transmitter coil 1013 and the fourth capacitance C4 can be selected such that the resonant frequency of the second tank circuit 1012 is greater than the first frequency fs. In this case, the fourth capacitance C4 can be selected so that the ratio of the first frequency fs to the resonant frequency of the second tank circuit 1012 may be set to greater than or equal to 0.5 and less than 1. Alternatively, the fourth capacitance C4 can be arranged in series with the transmitter coil 1013, and the fourth capacitance C4 can be selected such that the resonant frequency of the second tank circuit 1012 is less than the first frequency fs. In this case, the fourth capacitance C4 can be selected so that the ratio of the first frequency fs to the resonant frequency of the second tank circuit 1012 is greater than 1 and less than or equal to 1.5.
The overall effect of the inverter 101 is to reduce the peak voltage across the switching element Q1 whilst increasing the output power capability delivered to a receiver and hence to a load. For example, the inventors have found that, by using a first tank circuit 1011 with a resonant frequency equal to the second harmonic frequency of the switching signal from the drain of the switching element Q1 to ground, the peak voltage across the switching element Q1 is reduced from 3.5-4 times the input voltage, as in a conventional Class E inverter, to twice the input voltage. The first tank circuit 1011 effectively: (1) removes the second harmonic of the voltage developed across the switching element Q1 when the switching element Q1 is off by storing its energy and (2) releases the stored energy back to the circuit when the switching element Q1 is on.
The inverter 101 depicted in
As noted above, the first tank circuit 1011 in embodiments of the present invention may be tuned to any integer multiple of the first frequency fs; where the integer multiple is 2 or greater. The inventors have carried out investigations to determine which integer multiples provide better harmonic distortion than a conventional Class E inverter. More particularly, a hypothetical inductive power transfer system was considered with a transmitting coil inductance of 1 μH, an optimum reflected load of 6Ω, an output power of 100 W and a frequency of operation of 6.78 MHz. For simplification, lossless operation was also assumed. The harmonic content was analysed using state-space analysis.
As will be explained in more detail below, the present inventors have also investigated how to optimise the new inverter 101 to achieve high output power capability, high switching frequency and/or steady state operation. The present inventors have found that, by selecting the capacitances C1 and C2 and the switching duty cycle of the switching element Q1 (defined as the ratio of the time the switching element Q1 is on to the total time of the period, i.e. the sum of the switching element Q1 on-time and off-time in a period), the inductive power transfer transmitter 100 can be optimised for high output power capability, high switching frequency of the switching element Q1 and/or steady state operation.
More particularly, for maximum output power capability in a transmitter 100 in which the first tank circuit 1011 of the inverter 101 is tuned to twice the first frequency fs, or, taking into account tolerances between 1.95 and 2.05 of the first frequency fs, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is 0.867 or, taking into account tolerances between 0.767 and 0.967, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle of 0.375 or, taking into account tolerances, between 0.365 and 0.385.
To achieve 90% or greater of the maximum output power capability, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is between 0.8 and 1, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle between 0.35 and 0.40.
To achieve 80% or greater of the maximum output power capability, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is between 0.7 and 1, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle between 0.35 and 0.40.
Accordingly, a method for inductive power transfer in an embodiment is shown in
At step S402, the switching element Q1 is switched at the first frequency with a duty cycle greater than or equal to 0.35 and less than or equal to 0.40.
For maximum switching frequency in a transmitter 100 in which the first tank circuit 1011 of the inverter 101 is tuned to twice the switching frequency fs, or, taking into account tolerances between 1.95 and 2.05 of the first frequency fs, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is 1.567 or, taking into account tolerances between 1.467 and 1.667, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle of 0.3718 or, taking into account tolerances, between 0.3618 and 0.3818.
To achieve 90% or greater of the maximum switching frequency, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is between 1.2 and 3.7, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle between 0.35 and 0.40.
To achieve 80% or greater of the maximum switching frequency, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is between 1 and 5, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle between 0.35 and 0.40.
Accordingly, a method for inductive power transfer in an embodiment is shown in
At step S502, the switching element Q1 is switched at the first frequency with a duty cycle greater than 0.35 and less than 0.40.
For a steady state in a transmitter 100 in which the first tank circuit 1011 of the inverter 101 is tuned to twice the switching frequency fs, or, taking into account tolerances between 1.95 and 2.05 of the first frequency fs, the inventors have found that capacitances C1 and C2 should be selected such that the ratio of C1 to C2 is greater than or equal to 20, and the controller 102 should be arranged to switch the switching element Q1 with a duty cycle between 0.35 and 0.4.
Accordingly, a method for inductive power transfer in an embodiment is shown in
At step S602 the switching element Q1 is switched at the first frequency with a duty cycle greater than or equal to 0.35 and less than or equal to 0.40.
The advantages set out above, and those described below, can still be achieved even when the resonant frequency of the first tank circuit 1011 is not precisely an integer multiple, greater than one, of the first frequency fs. More particularly, the present inventors have found that the integer multiple with a tolerance of ±0.05 is sufficient to ensure correct operation. By way of example, when the resonant frequency of the first tank circuit 1011 is to be tuned to twice the first frequency fs, then correct operation can be achieved when the resonant frequency of the first tank circuit 1011 is between 1.95 and 2.05 times the first frequency fs. In more detail,
The following analysis provides further details of the above-described inverter and its properties. The analysis below, for sake of simplicity, considers cases without the use of a semi-resonant mode, but the analysis is equally applicable, without loss of generality, to the semi-resonant mode.
The output current io is sinusoidal and is given by
io(ωt)=im sin(ωt+φ) (1)
where im is the output current's magnitude and φ is its phase. For the period 0≤ωt<2πD the switch is ON, therefore
vDS(ωt)=0 for 0≤ωt<2πD (2)
iC
By applying KCL at the switch's drain node the switch's current is
is(ωt)=IIN−iL
Since the switch is ON, the total voltage across the series tuned L2C2 network is zero. The L2C2 network now is a source-free undamped circuit and its current (iL2) normalised with respect to the input DC current (IIN) is given by
where q1 is the ratio of the resonant frequency of L2C2 to the switching frequency and is given, by
The coefficients A1 and B1 are to be determined based on equation's boundary conditions.
For the period 2πD≤ωt<2π the switch is turned OFF, therefore
is(ωt)=0 for 2πD≤ωt<2π. (7)
By applying KOL at the switch's drain node the current in the series tuned L2C2 network is
The switch's voltage is equal to the total voltage across the L2C2 network and is given by
Differentiating the above equation results in
Substituting Eq. 10 in Eq. 8 and normalising with respect to the input current
Eq. 11 is a linear non-homogeneous second-order differential equation which has the following general solution
and the coefficients A2 and B2 are to be determined based on the equation's boundary conditions. The boundary conditions are determined from the current and voltage continuity conditions when the switch turns ON and OFF which can be described by
The current through capacitor C1 for the period 2πD≤ωt<2π is
iC
and normalising with respect to the input current and using Eq. 13 gives
The drain voltage for the period 2πD≤ωt<2π is
where τ is a dummy variable. Substituting the ZVS (vDS(2π)=0) and ZDS (iC1(2π)=0) conditions in the above equation gives the following two equations
Eqs. 16-19 and Eqs. 23-24 are six simultaneous equations that can be solved numerically to obtain the values of A1, A2, B1, B2, p and φ for specific values of q1, duty cycle D and k.
[Voltage and Current Waveforms]
Eq. 22 can be written as
The DC component (or average) of the drain's voltage is equal to the input voltage supply, i.e,
By substituting Eq. 27 in Eq. 25, the normalised drain voltage with respect to the input voltage can be written as
Using Eq. 15 the normalised switch's current with respect to the input DC current can be written as
By using the numerical solutions for A1, A2, B1, B2, p and φ, the voltage and current waveforms throughout the inverter can be plotted for given values of q1, duty cycle and k.
It can be noticed from the plotted waveforms that the switch's peak drain voltage and peak drain current and the shape of their waveform change according to the duty cycle. As the duty cycle decreases the switch's peak drain voltage increases and its peak drain current decreases. The switch's peak drain voltage decreases and its peak drain current increase as the duty cycle increases. The shape of the current through inductor L2 is mainly affected by the value of k. The current is almost sinusoidal at high k values and its frequency ratio to the switching frequency is equal to the value q1 over the entire switching period. The current becomes less sinusoidal, or contains additional harmonics, at low k values. For the case when q1=2 the slope of the switch's current at the instant when it is turned OFF is positive at a higher k, and is negative at a lower k.
[Input DC Resistance]
The DC component (or average) of the switch's current is equal to the DC input current, hence
Solving Eq. 30 for p
Substituting Eq. 31 in Eq. 15 gives the normalised value of im with respect to the input DC current
All the power supplied by the source will be consumed in the load, thus
Rearranging the above equation and using Eq. 33 gives in the input DC resistance seen y the source
[Voltage and Current Stresses]
The peak voltage across the switch can be calculated by differentiation Eq. 28 and setting it to zero
which leads to the following equation
An explicit solution does not exist for Eq. 37, it can however be solved numerically for specific values of q1, duty cycle and k. Another approach to determine the peak voltage across the switch is to search for a value for ωt that maximises the switch's voltage. The Matlab function fminbnd( ) can be used to determine the switch voltage peaks for a certain q1 value over a duty cycle range and a k.
The peak switch current can either occur during the switch ON period 0≤ωt<2πD or at the end of the switch ON period ωt=2πD. The peak switch current during the switch ON period can be obtained by differentiating Eq. 29 and Setting it to zero and solved for ωt
The calculated value of ωt should be substituted back into Eq. 29 and the evaluated peak switch current should be compared with the switch's current value at ωt=2πD and the switch's maximum current is the greater value of the two. Alternatively, the peak switch current can be found by searching for a value for ωt that maximises the switch's current.
[Power Output Capability]
The power output capability is defined as the ratio of the output power to the maximum voltage and current stresses of the switch. It is an indication of the switch utilization for a certain output power. It can be represented as
Since it has been assumed that the is ideal therefore all the power supplied by the source is consumed in the load, the output power capability can be written as
Using the solutions obtained from Eq. 37 & 38 the output power capability can be calculated for specific values of q1.
[Design Equations and Special Cases for the Class EF2 Inverter]
[Power Output Capability as a Function of k]
Since the inverter can operate at any given value of q1, duty cycle and k, it is of interest to operate the inverter 101 at its highest power output capability point. It will be assumed that series L2C2 is tuned to the second harmonic of the switching frequency, i.e. q1=2 (Class EF2). The aim now is for a given k to find the value of duty cycle that will result in the highest power output capability operation.
It can be noticed from
Based on the previous analysis the graphical solutions of the normalised values of the input resistance RDC, capacitors C1, C2 and residual impedance Lx can be plotted as shown in
Eqs. 42-47 can be used to determine the values of capacitors C1, C2 and C3 and the required duty cycle for a given k, load resistance RL, switching frequency and output network quality factor QL that will result in the highest power output capability operation.
[Special Case I: Solution for Maximum Power Output Capability Operation]
For the case when q1=2 the maximum power output capability is 0.1323 which occurs when the duty cycle is 0.375 and k is 0.867. In this case the values of A1=0.9394, A2=−0.8589, B1=−1.2405, B2=1.2276, p=1.9204, φ=2.5701 rad, q2=2.9349 and ∫2πD2πβ(ωt)=∫0.75π2πβ(ωt)=5.3241.
According to
According to
The values of the normalised output current, input resistance and maximum voltage and current stresses are given in Table 2 at the end of this analysis.
The switch's voltage, switch's current and the current through inductor L2 for this particular case are
Next, the values of further components will be determined for this particular case. Starting with C1, referring to Eqs. 26 & 27 the average voltage of the switch's voltage is
and using Eq. 35
Therefore the normalised reactance value of C1 with respect to the load is
Using Eq. 13 the normalised value of C2 is
Using Eq. 6 the normalised value of L2 is
The value of the residual impedance is equal to
where vx is the amplitude of the voltage across the residual impedance and is equal to
Using Eq. 28 vx is also equal to
Using Eq. 32 & 35 the normalised value of the residual impedance is
and the normalised reactance value of C3 is
[Special Case II: Solution for Operation at High k Values]
Case II corresponds to the previously discussed steady state case.
The analysis and design equations can be simplified for operation at a value of k higher than 20. The following assumptions can be concluded based on the previous sections as k begins to increase
k>20 (61)
p→0 (62)
q2≈q1 (63)
A2≈A1 (64)
B2≈B1. (65)
Applying the above assumptions to Eqs. 5 & 12 the current through inductor L2 for the period 0≤ωt<2π can be written as
The above equation shows that the current through inductor L2 is sinusoidal for the entire switching signal with a frequency equal to the resonant frequency of L2 and C2 which is equal to q1ω. The current in the switch when it is turned ON is
The harmonic content of the current in the switch consists of a DC component, a component at the fundamental switching frequency co and a component at the resonant frequency of L2C2 which here is q1ω. The components with frequency q1ω can be calculated using two quadrature current Fourier components at q1ω. These two quadrature Fourier components are equal to A1 and B1 respectively as follows
The current in capacitor C1 when the switch is turned OFF is
From Eq. 28 the voltage developed across capacitor C1 is
Substituting the ZITS (vDS(2π)=0) and ZDS (iC1(2π)=0) conditions in Eq. 71 gives the following two equations
Eqs. 68, 69, 73 & 74 are four simultaneous equations that can be solved numerically for im/IIN, φ, A1 and B1 for a given value of q1 and duty cycle.
The peak drain current can be obtained by differentiating Eq. 71 and setting it to zero which results in the following equation
which can be solved numerically. The peak drain voltage can be obtained by differentiating Eq. 71 and setting it to zero which results in the following equation
which can also be solved numerically. It should be noted that drain voltage may contain two local maximum points depending on the set duty cycle. Therefore the maximum drain voltage is the highest of the two local maximum voltages. The output power capability can then be calculated from Eq. 40.
The above equations can be used to proceed with the calculations of the values of the components and other parameters. However, by observing
From Eq. 34 the normalised input DC resistance is
and the output power is
From Eqs. 26 & 27 and using Eq. 77 and the solved value of ∫β′(ωt)dωt the normalised value of capacitor C1 is
From Eq. 58 the voltage across the residual impedance is
From Eq. 56 and using Eq. 77 and the solved value of im/IIN the normalised value of the residual impedance is
and from Eqs. 60 the normalised value of capacitor C3 is
The values of L2 and C2 should be chosen such that their resonant frequency is equal to 2ω and k is larger than 20.
[Special Case III: Maximum Switching Frequency]
The maximum frequency that the Class EF can operate at is when the value of C1 equals the output capacitance of the switch Co (assuming that the switch's output capacitance is linear). For the maximum output power capability case (q1=2, D=0.375, k=0.867) the maximum frequency at which the ZVS and ZDS conditions can be achieved is determined from Eq. 53
which is about 0.7 times that of the Class E inverter. For the case when k>20 the maximum frequency at which the ZVS and ZDS conditions can be achieved is determined from Eq. 79
which is about 0.7 times that of the Class E inverter.
By examining
which approximately equals to the maximum frequency of the Class E inverter.
However,
Similarly,
The design equations for this new particular case (maximum frequency case), which can be calculated in a similar manner to what has been done for Case I, are given in Table 2. The values of the normalised output current, maximum voltage and current stresses, input DC resistance and output power capability are also given in Table 2.
[Minimum Input Choke Inductance]
The minimum inductance value of the input choke will be determined here for all of the special cases above. When the switch is ON, the voltage across the input choke is
vL
and the current through the choke inductance is
The current in the input choke at the end of the ON period is
Therefore the peak-to-peak ripple in the input current is
The minimum input choke inductance required for the maximum peak-to-peak current ripple is
Using Eq. 34 the minimum input choke inductance can be written as
The above equation gives the minimum input choke inductance for a certain maximum input current ripple percentage. For the maximum output power capability case (Case I, q1=2, D=0.375, k=0.867) the minimum inductance for a 10% (ΔiL1/IIN=0.1) input ripple current is
which is about 2.7 times more than that of the Class E inverter.
For the case when k>20 (Case II) the minimum inductance for a 10% (ΔiL1/IIN=0.1) input ripple current is
which is about 0.8 times less than that of the Class E inverter.
For the maximum frequency case (Case III) the minimum inductance for a 10% ΔiL1/IIN=0.1) input ripple current is
which is about 1.2 times more than that of the Class E inverter.
[Efficiency]
The losses and efficiency will be considered for all special cases. The efficiency is defined as η=Po/PIN. Beginning with the input choke, it losses can be represented by a series resistor rf which includes the winding resistance and core losses. According to the first assumption, the current in the input choke is constant therefore the loss in the input choke is equal to
The switch conduction power loss due to its ON resistance rDS is determined first by calculating the rms value of the switch's current from Eq. 29 as follows
and the conduction power loss is
The power loss in the shunt capacitor C1 due to its resistance rC1 is determined first by calculation the rms value of it's current from Eq. 21 as follows
and the power loss is
The power loss in the series tuned L2C2 branch due to the ESR of the inductor rL2 and the resistance loss of the capacitor rC2 is first determined by calculated the rms current value of inductor L2 as from Eqs. 5 & 12 as follows
and the total power loss is
The power loss in the output load network L3C3 due to the inductor's ESR rL3 and the capacitor's resistance rC3 is
The turn-ON switching power loss of the switch is assumed to be zero if the ZVS condition is achieved. The turn-OFF switching power loss can be estimated as follows (according to M. K. Kazimierczuk, RF Power Amplifiers, 2nd ed. Chichester, UK: John Wiley & Sons Ltd, 2015.). The switch current during turn-OFF tf can be assumed to decrease linearly. Using Eq. 29 the switch's current can be represented as
and the current in the shunt capacitor C1 can be approximated by
The voltage, across the switch is
and using Eqs. 26 & 27 the voltage across switch can be represented as
The average power dissipated in the switch is
The efficiency of the inverter is
Table 1 lists the numerical evaluations for all the power loss equations for the special cases described in the previous section.
[Summary of Design Equations and Parameters for all Special Cases of the Class EF2 Inverter]
Table 2 summarises all the design equations and parameters for all the special cases of the Class EF2 inverter in comparison with the Class E inverter.
[Semi-Resonant Operation (Impedance Transformation)]
The reflected load of the secondary side in an inductive power transfer system tends to be low, generally between 1-10Ω. Referring to
The impedance of the equivalent resistance (REq) and the equivalent inductance (LEq) due to the addition of Cres is
Therefore the equivalent resistance is
the equivalent inductance is
and the equivalent loaded quality factor is
Eqs. 110-112 can be incorporated in the design equations for each special case of the Class EF2 inverter above without changing the results.
[Experimental Verification and Results]
Experimental verification for all of the defined special cases of the Class EF2 inverter have been carried out on a 23 W prototype with a switching frequency of 6.78 MHz was chosen for Cases I and II, and II a 8.60 MHz switching frequency was chosen for Case III to demonstrate its capability to operate at higher frequencies. In order to ensure a fair comparison, the same MOSFET, load resistance and inductance L3 were used when verifying all of the special cases.
[Experimental Set-Up]
The inductance of the MOSFET's package should be as small as possible to allow for the megahertz switching frequencies to be achieved and to allow for ‘clean’ voltage waveforms to be recorded. In addition, the MOSFET's total gate charge should be reasonably low to reduce gate drive losses. Finally, the MOSFET's output capacitance should be as low as possible, ideally below 500 pF at a certain input voltage. This is important to firstly prevent the MOSFET's output capacitance from achieving the desired switching frequencies and secondly, to reduce the effect of the non-linearity of the MOSFET's output capacitance on the performance of the inverter. The MOSFET SiS892ADN 100V, 28 A from Vishay which is available in a surface mount 1212 package was found to be suitable. It's maximum ON resistance is 0.047Ω and has a maximum input capacitance of approximately 850 pF. Its output capacitance is below 400 pF for DC drain voltages above 16V. The gate driver UCC27321 from Texas Instruments was used and a maximum gate drive voltage of 7.0V was set for all cases.
All the capacitors used were multilayer ceramic capacitors from AVX Corporation. The capacitors belong to the manufacturer's ‘Hi-Q’ series and are designed for RF and microwave applications. Their ESR is below 0.04Ω for frequencies below 30 MHz. Inductance L3 had to be an air-core inductor to avoid the excessive power losses and saturation that are associated with using magnetic cores at high frequencies. It was formed using a coil that consisted of two turns with a diameter of approximately 15 cm and using 4 AWG copper wire. It's inductance was measured to be approximately 1.25 μH and its ESR is approximately 0.215. The load consisted of three paralleled 15Ω 35 W thick film resistors from Bourns. Each resistor had a maximum inductance of 0.1 μH. The current probe N2783A from Keysight Technologies was used to record the output current. The total inductance of the current probe and the load resistors was assumed to be 0.1 μH according to their datasheets and was added to the inductance of L3. The output power was calculated using the reading of the current probe which had accuracy of about 2%.
[Maximum Power Capability Case (Case I)]
For Case I, the values of capacitors C1, C2 and C3, in addition to all other parameters, were calculated for a switching frequency of 6.78 MHz using the design equations given in Table 2 and their values are all listed in Table 3 below. The input voltage was calculated to be 30.25V and the MOSFET's output capacitance at this voltage was deducted for the calculated value of C1. Capacitors C2 and C3 each consisted of four parallel capacitors. The difference between the used total capacitance value of C2 and the theoretical value is due to the parasitic capacitance of the PCB. The value of inductor L2 was calculated to be 202.61 nH. This inductor was formed by using two paralleled 430 nH air-core inductors from Coilcraft (2929SQ series). The shape of the parallel coils were slightly altered to achieve the desired inductance. According to Eq. 50 the current in inductor L2 contains several frequency components (1st, 2nd and 3rd), therefore the inductor's ESR will be different for each one of these components. For simplification, the ESRs at 6.78 MHz, 13.56 MHz and 20.34 MHz were calculated according to the manufacturer's datasheet and their average was considered as a constant ESR for the entire switching period which was equal to 0.18Ω. Adding the DC resistance of the paralleled coils and the ESR of capacitor C2 makes the total ESR in the L2C2 branch approximately 0.20Ω.
The measured input and output powers, input current and maximum MOSFET voltage are listed in Table 3 and are compared with their theoretical values. It can be noticed that error between measurements and theory is low. The recorded waveforms of the MOSFET's drain voltage and output current are shown in
[Maximum Frequency Case (Case III)]
The verification and design process for Case III was similar to that of Case I. The switching frequency was increased to 8.60 MHz to show that this case can be operated at higher frequencies. Also, this specific frequency was chosen in order to keep the same parallel coils for inductor L2 that were used in Case I. The average ESR for inductor L2 was now approximately 0.25Ω.
The measured input and output powers, input current and maximum MOSFET voltage for this case are listed in Table 3. The error between measurements and theory for this case are minor. The recorded waveforms of the MOSFET's drain voltage and output current are shown in
[k=20 Case (Case II)]
For Case II, the switching frequency was decreased back to 6.78 MHz. A k value of 20 was chosen in order to obtain the lowest inductance value for L2 which was calculated to be 4.81 μH. The magnetic core T106-2 from Mircometals had to be used to achieve this inductance. The input voltage for a 23 W output power was calculated to be approximately 15.5V. Although the MOSFET's output capacitance at this voltage was below the required C1 capacitance, it's non-linearity in addition to the losses and saturation of the magnetic core of inductor L2 were quite significant and had an impact on inverter's performance. Therefore the SPICE model was used to verify the performance of the inverter in this case by simulating the experimental results. Table 2 compares the values of all components and the measured input and output powers, input current and maximum MOSFET voltage in comparison with those of the SPICE simulation.
[Comparison with Class E Operation]
The designed Class EF inverter was then compared with a Class E inverter in order to prove that Case I and III can be more efficient. For the Class E inverter, the switching frequency was kept at 6.78 MHz. The component values, input and output powers, input current and maximum MOSFET voltage were calculated from the design equations in M. K. Kazimierczuk, RF Power Amplifiers, 2nd ed. Chichester, UK: John Wiley & Sons Ltd, 2015. The calculated input voltage was 16V and it was also found that the non-linearity of the MOSFET's output capacitance affected the performance of the inverter, therefore the SPICE model was used for verification.
The component values and measured parameters are listed in Table 3. The recorded MOSFET's drain voltage and output current waveforms shown in
The analysis above shows that the following conclusions can be made regarding the Class EF2 inverter:
The foregoing description of embodiments of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Alternations, modifications and variations can be made without departing from the spirit and scope of the present invention.
Number | Date | Country | Kind |
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1501733.8 | Feb 2015 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2016/052154 | 2/2/2016 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2016/124577 | 8/11/2016 | WO | A |
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Number | Date | Country | |
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20180034383 A1 | Feb 2018 | US |